Method for performing single-stage cranioplasty reconstruction with a clear custom cranial implant

ABSTRACT

A method for single-stage cranioplasty reconstruction includes prefabricating a clear craniofacial implant, creating a cranial, craniofacial, and/or facial defect, positioning the clear craniofacial implant over the cranial, craniofacial, and/or facial defect, tracing cut lines on the clear craniofacial implant as it lies over the cranial, craniofacial, and/or facial defect, cutting the prefabricated clear custom craniofacial implant along the hand-marked lines for optimal fit of the clear implant within the cranial, craniofacial, and/or facial defect, and attaching the final clear craniofacial implant to the cranial, craniofacial, and/or facial defect with standard fixation methods of today.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/489,036, filed Apr. 24, 2017, entitled “METHOD FOR PERFORMING SINGLE-STAGE CRANIOPLASTY RECONSTRUCTION WITH A CLEAR CUSTOM CRANIAL IMPLANT.”

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention generally relates to the field of surgery. In particular, the invention relates to the brain and skull, the art of reconstructing skull defects (i.e., cranioplasty), neurosurgery, neurology, neuroplastic and reconstructive surgery, and craniofacial plastic surgery.

2. Description of the Related Art

Craniectomies requiring skull reconstruction (i.e., cranioplasty) are often indicated for a multitude of etiologies including decompression (i.e., skull removal) following stroke or traumatic brain injury, bone flap infection (i.e., osteomyelitis) and/or bone flap resorption following previous neurosurgery, and/or oncological ablation for masses involving the underlying brain and/or skull. In the setting of traumatic brain injuries with cerebral edema, stroke (i.e., brain ischemia) with bleeding, and/or autologous bone flap resorption or osteomyelitic infections requiring removal, delayed cranioplasties are necessary at a secondary stage.

In fact, nearly 250,000 primary brain tumors/skull-based neoplasms are diagnosed each year resulting in a range of 4,500-5,000 second-stage implant cranioplasties per year (Berli J U, et al., “Immediate Single-Stage Cranioplasty Following Calvarial Resection for Benign and Malignant Skull Neoplasms Using Customized Craniofacial Implants,” The Journal of Craniofacial Surgery, Vol. 26, No. 5, Sept. 2015).

The common types of cranial implants used today, in instances where the exact bone defect shape and size is known well in advance, are made most often from a variety of safe biomaterials (i.e. manmade), including titanium mesh, porous hydroxyapatite (HA), polymethylmethacrylate (PMMA), porous polyethylene, and polyether-ether-ketone (PEEK), among others. Of note, the most common “off-the-shelf” solution used by neurosurgeons and reconstructive surgeons is titanium mesh implants bent to serve as a “bridge”—simply spanning the skull defect from one side to another to create a non-specific curvature and protection barrier for the brain. The thin titanium mesh (which is 1 millimeter thick versus the normal skull thickness of 4-5 millimeters) accompanies several drawbacks and limitations including 1) non-anatomical thickness and secondary dead-space underneath, 2) a need to overlap neighboring skull areas for bridging and stability which can lead to visible deformities and scalp irregularities within the anterior craniofacial regions (i.e., non-hair bearing regions), and 3) a high risk of extrusion through the scalp when placed under thin and/or irradiated scalps.

A distinct subset of skull reconstruction patients includes craniectomy defects following oncological resection of calvarial lesions and/or brain tumors invading the skull. For this type of tumor ablative surgery, where tumors and/or processes (i.e., radiation therapy) involve the skull, cranioplasties to date have previously been performed using either 1) suboptimal hand-molding techniques with “off-the-shelf” products” or 2) a delayed, second surgery allowing the design and fabrication of a customized cranial implant. Now, with the advent of computer-aided design/manufacturing (CAD/CAM) and customized craniofacial implants, more suited alternatives are becoming widely available and have been published (Berli J U, et al., “Immediate Single-Stage Cranioplasty Following Calvarial Resection for Benign and Malignant Skull Neoplasms Using Customized Craniofacial Implants,” The Journal of Craniofacial Surgery, Vol. 26, No. 5, Sept. 2015).

Using CAD/CAM fabrication, near-perfectly shaped custom cranial implants can be ordered and pre-fabricated with exact patient-specific curvatures to an oversized dimension, and then modified around the edges intra-operatively for an exact fit following bone/brain tumor resection as described by Gordon et al. (See, Gordon C R, et al., “Discussion of Usefulness of an Osteotomy Template for Skull Tumorectomy and Simultaneous Skull Reconstruction,” The Journal of Craniofacial Surgery, Vol. 27, No. 6, Sept. 2016; Berli J U, et al., “Immediate Single-Stage Cranioplasty Following Calvarial Resection for Benign and Malignant Skull Neoplasms Using Customized Craniofacial Implants,” The Journal of Craniofacial Surgery, Vol. 26, No. 5, Sept. 2015.)

To accomplish this approach, preoperative imaging such as computed tomography (CT) is used ahead-of-time to identify the patient's exact skull and brain anatomy and the patient's exact skull curvature (since all patients have different curvatures based on region, gender, and age). However, the exact cranial defect size (following oncological resection) is truly unknown until the final tumor and local disease extension are removed to completion with visual confirmation—since in some instances, there is tumor extension into neighboring regions (i.e., bone, brain) unseen on pre-operative imaging which then requires a more extensive resection than originally planned. As such, for one to follow true oncological principles and to make sure the surgeon is unrestricted in removing all concerning areas of disease (thereby decreasing all risk of recurrence), the prefabricated custom implant must be designed with extraneous material around the edges—to be able to accommodate the unexpected tumor size and whether or not a larger size is needed, as opposed to what was originally imagined. Therefore, the pre-operative CT scan images are used to virtually plan the surgical skull cuts in an oversized fashion around the bone/brain tumor with excess of several inches (up to 5 to 7 centimeters, on average, of excess implant material) based on the tumor's exact location (and to allow the geometric design of the three-dimensional (3D) custom cranial implant to be created in an ^(“)oversized fashion”). But as opposed to the current “off-the-shelf” products mentioned previously, this customized implant made of a safe biomaterial remains advantageous since it's “patient-specific” with respect to the individual's exact craniofacial convexity and curvature equating to minimal-to-no deformity after surgery.

In summary, the “single-stage cranioplasty” method and pre-fabricated custom implant with excess dimensions, described here, is designed to account for any additional bone/soft tissue loss that may become necessary to remove during the surgery (that is, due to unanticipated local brain or skull invasion, desire to decrease risk of recurrence and enlargement of resection limits, an unknown tumor pathology grade until resected and sent for frozen analysis with pathology, etc.). Therefore, after resecting the bony/soft tissue region of interest, the surgeon is forced to shave down and modify the oversized custom cranial implant to fit exactly within the resected area using artistic hand-eye coordination, dedicate significant time and labor intra-operatively (up to 80 minutes), and work back and forth in the operating room between the patient's final anatomy and a sterile back table to achieve an ideal fit, as described by Berli J U, et al. (“Immediate Single-Stage Cranioplasty Following Calvarial Resection for Benign and Malignant Skull Neoplasms Using Customized Craniofacial Implants,” The Journal of Craniofacial Surgery, Vol. 26, No. 5, Sept. 2015). Similarly, a surgeon could remove normal bone in order to place an intercranial device above an area of brain pathology amenable to local intervention, as described by Gordon et al. in International Patent Application PCT/US2016/030447, filed May 2, 2017, entitled “LOW PROFILE INTERCRANIAL DEVICE,” (published as WO 2017/039762) (762 Publication), which is incorporated herein by reference.

As such, current techniques for modifying the oversized custom cranial implant for “single-stage cranioplasty” are inefficient and far from optimal given the abundant amount of time and artistic labor needed to perform “back-and-forth” size modification with a handheld burr. With significant operative times being extended, the patient's peri-operative morbidity is increased as well as are the fixed operating rooms costs surrounding prolonged surgery. Therefore, newer strategies have been developed and described for instance using “opaque” customized implants, such as disclosed in the inventor's own U.S. Patent Application Publication No. 2017/0000505, entitled “Computer-Assisted Craniomaxillofacial Surgery.”

Still further, the current market only offers these opaque (or non-clear) cranial implants (described in U.S. Patent Application Publication No. 2017/0000505) with zero visibility and zero translucency—which is a significant deterrent to the neurosurgeon or reconstructive craniofacial surgeon hoping to perform single-stage cranioplasty. With the abundant availability of only “opaque” implants, on the current market, there is increased complexity and artistic demand challenging all surgeons when faced with this difficult scenario. These demands are demonstrated in FIGS. 1A-G which show a cranioplasty performed with an opaque cranial implant. As the pictures show, the procedure requires hand-modification following skull tumor resection, and its difficulty is exponentially increased. The hand modification is highly difficult due to the inability to see through the implant and NOT being able to appreciate the underlying skull margins underneath when placed in-situ. Of note, one can appreciate the unintentional perimeter defects secondary to one's ability to not see clearly through the implant—which is related to either “undershaving” or “overshaving” the implant's borders—as a way to make the oversized implant fit. However, undershaving leaves the implant too small and increases risk for resulting deformity. But in an ideal setting, a “clear” customized cranial implant (made of a safe biomaterial with complete translucency) would be a much welcomed advance to the fields of neurosurgery and skull reconstruction—both to lower accompanying complexity and to drastically quicken the operation.

Accordingly, a surgical method that allows surgeons to resize, adjust, modify or trim alloplastic or bio-engineered cranial implants during cranioplasty (i.e., skull reconstruction) surgery to fit the surgical cuts, defects, and/or preexisting deformities in a streamlined fashion with reduced complexity, operative time, and/or demand for artistic hand-eye coordination, or generally overcome the limitations of current technology and surgical methods, described here, would be welcome in the art. While Gordon et al. have previously developed surgical method, techniques and systems using a robot-assisted and/or laser-assisted method as described in U.S. Patent Application Publication No. 2017/0000505, these novel technologies were developed solely based on the assumption that one would be forced to use the commonly-available, “opaque” customized cranial implants. Thus, up until this time, there have been no developments taking advantage of specific implant biomaterials that are clear and/or newfound implant translucency in the manner disclosed and claimed in accordance with the present invention.

SUMMARY OF THE INVENTION

It is, therefore, an object of the present invention to provide a method for cranioplasty. The method includes first prefabricating a clear craniofacial implant with complete transparency and clarity based upon information generated by preoperative scans. The method also includes creating a cranial, craniofacial, and/or facial defect, and positioning the clear craniofacial implant over the cranial, craniofacial, and/or facial defect. Thereafter, cut lines are traced by hand on the clear craniofacial implant (since one can see the bony edges of the cranial, craniofacial and/or facial defect through the clear craniofacial implant) as it lies over the cranial, craniofacial, and/or facial defect, wherein a boundary of the cranial, craniofacial, and/or facial defect is easily viewable through the clear craniofacial implant as a result of the clear construction of the craniofacial implant. The clear custom craniofacial implant is cut along the traced cut lines drawn by hand for optimal fit of the craniofacial implant along the cranial, craniofacial, and/or facial defect and to create a final clear craniofacial implant with exact fit. The final clear craniofacial implant is attached to the cranial, craniofacial, and/or facial defect. This procedure would not be possible in the setting of a standard, “opaque” implant.

It is also an object of the present invention to provide a method for cranioplasty wherein the clear craniofacial implant is composed of PMMA.

It is further an object of the present invention to provide a method for cranioplasty including the step of positioning the clear craniofacial implant over the cranial, craniofacial, and/or facial defect prior to the step of tracing cut lines.

It is another object of the present invention to provide a method for cranioplasty wherein the step of positioning includes placing the clear craniofacial implant over the cranial, craniofacial, and/or facial defect in a desired orientation based upon a unique anatomy of an outer surface of a skull surrounding the cranial, craniofacial, and/or facial defect.

It is a further object of the present invention to provide a method for cranioplasty wherein the step of tracing includes tracing a periphery of the cranial, craniofacial, and/or facial defect directly onto the clear cranio facial implant using a sterile intra-operative marking pen by being able to see through the clear craniofacial implant while “in-site”.

It is another object of the present invention to provide a method for cranioplasty wherein the step of positioning includes placing the clear craniofacial implant over the cranial, craniofacial, and/or facial defect in a desired orientation based upon a unique anatomy of an outer surface of a skull surrounding the cranial, craniofacial, and/or facial defect which is visible through the clear craniofacial implant.

It is also an object of the present invention to provide a method for cranioplasty wherein the step of cutting includes trimming the clear craniofacial implant using medical grade tools, computer-assisted, and/or robot-assisted devices in an operating room along boundaries defined by the traced cut lines.

It is another object of the present invention to provide a method for cranioplasty including the steps of identifying a diseased portion associated with aberrant craniofacial and/or brain anatomy and generating a computer-readable reconstruction of a patient's anatomy associated with the diseased portion for the purpose of designing and fabricating the clear craniofacial implant, or to provide a method of placing intercranial device as described in the '762 Publication over an area of brain pathology amenable to local intervention (i.e., by removing normal bone).

It is also an object of the present invention to provide a method for cranioplasty wherein the step of creating a cranial, craniofacial, and/or facial defect includes cutting out a portion of a skull to be replaced with the clear craniofacial implant.

It is another object of the present invention to provide a method for cranioplasty wherein a neurological device, for example, as described in the '762 Publication, with constant or intermittent function is incorporated within the clear craniofacial implant.

It is a further object of the present invention to provide a method for cranioplasty wherein the neurological device is a monitoring device or device for treating a neurological disorder.

It is also an object of the present invention to provide a method for cranioplasty wherein the cranioplasty is a single-stage cranioplasty.

It is another object of the present invention to provide a method for cranioplasty wherein the clear craniofacial implant includes an etching or a marking.

It is further an object of the present invention to provide a method for cranioplasty wherein the etching or marking indicates a desired implanted orientation of the clear craniofacial implant.

It is also an object of the present invention to provide a method for cranioplasty wherein the etching or marking identifies anatomy beneath the defect, a tumor sight, an aneurysm location, or a functional component (i.e., brain pathology).

It is another object of the present invention to provide a method for cranioplasty wherein the etching or marking identifies a prescription, a disease state, or a date of surgery, or type of implantable neurotechnology housed within the clear craniofacial implant.

It is another object of the present invention to provide a method for cranioplasty wherein the step of creating a cranial, craniofacial, and/or facial defect includes cutting out a portion of a skull to be replaced with the clear craniofacial implant in instances where an intercranial device as described in the '762 publication would be valuable to the neurosurgical patient.

It is a further object of the present invention to provide a method for cranioplasty wherein a neurological device is incorporated within the clear craniofacial implant in an effort to reduce visible deformity and/or pressure on the scalp risking extrusion.

It is also an object of the present invention to provide a method for cranioplasty wherein the neurological device is a monitoring device or device for treating a neurological disorder, hydrocephalus shunting device with pressure monitor, or direct medicine delivery device.

It is another object of the present invention to provide a method for cranioplasty wherein the cranioplasty is a single-stage cranioplasty, meaning that the skull defect dimensions are unknown prior to surgery.

It is also an object of the present invention to provide a method for cranioplasty wherein the etching(s) or marking(s) indicate a desired implanted orientation of the clear craniofacial implant based on its relation to the brain anatomy underneath.

Other objects and advantages of the present invention will become apparent from the following detailed description when viewed in conjunction with the accompanying drawings, which set forth certain embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-G show a cranioplasty performed with an opaque cranial implant.

FIGS. 2A-2F, 3A, and 3B illustrate together a schematic representative of the present method for single-stage cranioplasty reconstruction using a clear craniofacial implant and the final result with the embedded final clear craniofacial implant, wherein FIGS. 2A-2F show the steps from a single-stage cranioplasty reconstruction in accordance with the present invention and FIGS. 3A and 3B respectively show pre-operative (left) and post-operative (right) CT scans showing a large left sided skull tumor and post-resection views exhibiting ideal symmetry and optimal implant location using a clear custom cranial implant in accordance with the present invention.

In particular, FIG. 2A shows cutting out the diseased portion of the skull or that portion of the skull required to access diseased tissue of the brain or other portion of the anatomy, and thereby creating a cranial, craniofacial, and/or facial defect.

In particular, FIG. 2B shows a perspective view and a top plan view of the removed portion of the skull.

In particular, FIG. 2C shows positioning the prefabricated clear custom craniofacial implant over the cranial, craniofacial, and/or facial defect created by the removal of the diseased anatomical feature.

In particular, FIG. 2D shows tracing cut lines with a hand-held sterile marker on the prefabricated clear custom craniofacial implant as it lies in-situ over the cranial, cranio facial, and/or facial defect.

In particular, FIG. 2E shows cutting the prefabricated clear custom craniofacial implant along the tracing cut lines for optimal fit of the prefabricated clear custom craniofacial implant along the cranial, craniofacial, and/or facial defect and to create the final-size/shape of clear craniofacial implant for exact fit.

In particular, FIG. 2F shows attaching the final clear craniofacial implant to the patient.

In particular, FIG. 3A is a pre-operative CT scan.

In particular, FIG. 3B is a post-operative CT scan.

FIG. 4 is a perspective view of an alternate cranial implant in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The detailed embodiments of the present invention are disclosed herein. It should be understood, however, that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as a basis for teaching one skilled in the art how to make and/or use the invention.

Referring to FIG. 2A-2F, 3A, 3B, and 4, the present invention relates to a novel method for performing single-stage cranioplasty with “clear” customized implants (see for example, FIGS. 2C and 2D showing the clear custom craniofacial implant 10 held directly above a skull tumor defect following extirpation (that is, the cranial, craniofacial, and/or facial defect 100 as discussed below) prior to single-stage modification). As explained above in the Background of the Invention, the method of “single-stage cranioplasty” is defined as a surgery where the surgeon intends to create a complicated, full-thickness, three-dimensional defect in the craniofacial skeleton in real-time and then replace the subsequent craniofacial bone (and/or soft tissue) with an oversized patient-specific custom implant requiring on-table size modification—versus using an “off-the-shelf” biomaterial with no form of customization specific to the patient's anatomy. Or, this could be applicable to situations when the surgeon is notified of an upcoming case with little notice and does not have time to obtain other types of skull implants which may take more time to manufacture, like those made of porous polyethylene, for example. Furthermore, clear implants for single-stage cranioplasty also accompany a significant advantage of seeing the brain anatomy underneath during the case which allows for critical viewing of potential bleeding sources, such as the tumor cavity or sagittal sinus, for example. As such, this novel “translucency” of the clear custom craniofacial implant 10 equates to both a safer, and more effective, method for single-stage cranioplasty.

In accordance with the present invention, and as will be explained below in greater detail, the present invention makes use of prefabricated custom craniofacial implants 10 made of a “clear” translucent material, man-made alloplastic or other tissue engineered material, to allow and improve a surgeon's ability to view a cranial, craniofacial, and/or facial defect 100, and brain anatomy distal (i.e., underneath) to the prefabricated clear custom craniofacial implant 10 when placed into an overlapping position (see FIG. 2A-2F, 3A, and 3B showing a single-stage cranioplasty reconstruction in accordance with the present invention) relative to the cranial, craniofacial and/or cranial defect 100. In accordance with the single-stage cranioplasty reconstruction shown in FIGS. 2A-2F, 3A, and 3B involving a large skull tumor and clear custom implant 10 the two distinct advantages of the present invention are depicted—one being streamlined customization, and the other being critical viewing of brain-related structures for potential bleeding risk during the case.

Of note, one can appreciate the minimal perimeter defects seen at time of inset following intra-operative size modification of a “clear” customized craniofacial implant 10—which required only 8 total minutes for real-time, size modification. The reduced time and final outcome is completely related to the enhanced value of the implant's clear translucency—and the required time is about 90% less when compared to the previous cases described by the inventor's team in instances of using an opaque implant. By allowing the surgeon to see through the prefabricated “clear” custom cranio facial implant 10 and directly view the cranial, cranio facial, and/or facial defect 100 and brain anatomy over which the craniofacial implant 10 is to be positioned, the surgeon can save significant time and effort in matching the cranial, craniofacial, and/or facial defect 100 directly to the prefabricated clear custom craniofacial implant 10, without the use of multiple estimations or templates. Seeing through the clear custom craniofacial implant 10 also allows the surgeon to choose where to reshape the prefabricated clear custom craniofacial implant 10 and form the final clear craniofacial implant 10′ that will ideally fit the cranial, craniofacial, and/or facial defect 100. This newfound advantage of complete clarity and enhanced visibility through the craniofacial implant 10 described herein provides several unprecedented advantages specific to “single-stage cranioplasty,” including 1) ease-of-use with drastic reduction in operative times, 2) a new found ability to provide real-time visibility to pertinent anatomy underneath like exact bone edge dimensions dictating implant size modification, 3) the potential to discover brain-related bleeding underneath which requires electrocautery and can help to prevent re-operations related to post-operative bleeding, and 4) visualize periodic dural pulsations suggestive of healthy brain parameters. As such, this invention drastically reduces the time needed for reshaping and matching the prefabricated clear custom craniofacial implant 10 by around ten-fold, which now ranges between 8 and 10 minutes in some instances performed by the inventor, Dr. Gordon (instead of up to 80 minutes, as reported by Berli et al, J Craniofacial Surgery Vol. 26, No. 5, Sept. 2015.).

As those skilled in the art will appreciate, and as mentioned above, prefabricated custom craniofacial implants manufactured for reconstruction are inherently larger than the cranial, craniofacial, and/or facial defect created during surgery to adequately fill the cranial, craniofacial, and/or facial defect. In accordance with a preferred embodiment of the present invention, the clear custom craniofacial implant 10 with full transparency is a prefabricated implant such as a 3rd-party sourced alloplastic or tissue-engineered implant, preferably manufactured from clear poly(methyl methacrylate) (PMMA) or any other clear biocompatible material suited for safe use in craniofacial reconstruction. While a clear PMMA craniofacial implant is used in accordance with a preferred embodiment as discussed herein, it is appreciated the prefabricated clear custom craniofacial implant 10 may include a polymer, metal, bioengineered material, or any combinations thereof for which may also be clear. For example, the prefabricated clear custom craniofacial implant 10 may include any biomaterial that may allow enhanced visibility with complete translucency. In addition, it is appreciated the use of the term cranio facial implant herein is intended to include all clear implants that may be used in conjunction with skull reconstruction procedures, facial reconstruction, or any combination thereof. Regardless of the material construction employed in the fabrication of the clear prefabricated custom craniofacial implant, the implant must be completely translucent to provide the advantages described herein, which include 1) decreased operative times since underlying anatomy is assessed in superimposed fashion, 2) decreased blood loss for patient since the implant reconstruction is completed much faster, 3) decreased anesthesia and operative times, 4) decreased costs to hospital since surgery is abbreviated, and 5) reduced demand for artistic, hand-eye coordination, additional labor and/or work effort provided by the reconstructive surgeon. As used herein the term “clear” is intended to refer to a material that is substantially completely transparent (for example, the craniofacial implant is completely transparent with the exception of a neurological device(s) that might be integrated into the craniofacial implant and which does not otherwise impede the ability to achieve the underlying principles of the invention) and exhibits the property of transmitting rays of light through its substance so that bodies situated beyond or behind can be distinctly seen when looking through the material.

In addition to the direct advantages associated with the single-stage cranioplasty reconstruction, the craniofacial implant being “translucent” also allows for real-time transmission of light, which is critical for future applications related to any and all battery-powered, low-profile intercranial devices capable of neuromodulation (i.e. implanted functional RNS systems like NeuroPace) and capable of sending wireless electrocorticography (ECoG) signals for data collection, interpretation, treatment, and intervention; and a multitude of other wavelength-related mediums like optical coherence tomography (OCT) imaging and ultrasound imaging—as described by Gordon et al in International Patent Application PCT/US2016/030447, filed May 2, 2016 entitled “LOW PROFILE INTERCRANIAL DEVICE” (published as WO 2017/039762), and U.S. patent application Ser. No. 15/669,268, filed Aug. 4, 2017, entitled “METHOD FOR MANUFACTURING A LOW-PROFILE INTERCRANIAL DEVICE AND THE LOW-PROFILE INTERCRANIAL DEVICE MANUFACTURED THEREBY” (published as U.S. Patent Application Publication No. 2018/0055640), which claims the benefit of U.S. Provisional Patent Application 62/381,242, filed Aug. 30, 2016, entitled “METHOD FOR MANUFACTURING A LOW-PROFILE INTERCRANIAL DEVICE AND THE LOW-PROFILE INTERCRANIAL DEVICE MANUFACTURED THEREBY,” all of which are incorporated herein by reference. In addition, Dr. Gordon and team published a “first in-human” experience article related to this novel invention (Gordon C, et al, “First In-human experience with complete integration of neuromodulation device within a customized cranial implant,” Operative Neurosurgery 2017; 10 (6): 1-7).

As those skilled in the art will appreciate single-stage implant cranioplasty involves the surgical rebuilding and/or reconstruction of portions of the craniomaxillofacial skeleton to correct deformities (e.g., following trauma) and/or defects with unanticipated dimensions created in real-time—such as those involving tumor extirpation. Preoperative imaging such as CT or MRI identifies the patient anatomy. The surgery is planned using virtual pre-operative imaging to help identify an area of disease (e.g., the tumor) requiring resection and reconstruction. In addition to identifying diseased portions of the craniofacial anatomy, diseased portions of the brain anatomy may be identified and addressed in the implantation of an intercranial device(s) including neurotechnology 20 with constant or intermittent function as described in the '762 Publication (see, for example, FIG. 4) wherein the intercranial device is substantially clear and functions in the same manner as the clear custom craniofacial implant 10 described herein. Such neurological devices 20 include, but are not limited to, hydrocephalus shunt valve/pressure monitor, direct medicine delivery device, microchip polymer delivery device, radiation therapy device, functional neuromodulation device, etc. Bony cuts are planned and the prefabricated clear custom craniofacial implant 10 is designed to fit into the resected region following planned modification of the prefabricated clear custom craniofacial implant 10 (that is, the creation of the final clear craniofacial implant 10′). See, for example, FIG. 2F showing the clear custom craniofacial implant with ideal fit in place following tumor resection and optimal reconstruction, and with minimal gaps along skull-implant interface.

Still further, and considering the vast array of neurosurgical techniques and neurological devices that might be used in conjunction with the methodology underlying the present invention, the clear custom craniofacial implant may be manufactured to allow for the transmission of waves other than optical light waves, for example, the clear custom craniofacial implant may be sonolucent (that is, allowing passage of ultrasonic waves without production of echoes that are due to reflection of some of the waves) or radiolucent (that is, allowing passage of radio waves without production of echoes that are due to reflection of some of the waves). By way of example, the clear custom craniofacial implant 10 may be manufactured in a manner allowing for the transmission of ultrasonic waves as described in U.S. Pat. No. 9,044,195, entitled “IMPLANTABLE SONIC WINDOW,” ('195 Patent) which is incorporated herein by reference. As explained in the '195 Patent, a strong, porous sonically translucent material through which ultrasonic waves can pass for purposes of imaging the brain is employed, wherein the material is a polymeric material, such as polyethylene, polystyrene, acrylic, or poly(methyl methacrylate) (PMMA). In addition, U.S. Pat. No. 9,535,192, entitled “METHOD OF MAKING WAVEGUIDE-LIKE STRUCTURES,” ('192 Publication) and U.S. Patent Application Publication No. 2017/0156596, entitled “CRANIAL IMPLANTS FOR LASER IMAGING AND THERAPY,” ('596 Publication) both of which are incorporated herein by reference, making waveguide-like structures within optically transparent materials using femtosecond laser pulses wherein the optically transparent materials are expressly used in the manufacture of cranial implants. The '596 publication explains the use of optically transparent cranial implants and procedures using the implants for the delivery of laser light into shallow and/or deep brain tissue. The administration of the laser light can be used on demand, thus allowing real-time and highly precise visualization and treatment of various pathologies. Further still, Tobias et al. describe an ultrasound window to perform scanned, focused ultrasound hyperthermia treatments of brain tumors. Tobias et al., “ULTRASOUND WINDOW TO PERFORM SCANNED, FOCUSED ULTRASOUND HYPERTHERMIA TREATMENTS OF BRAIN TUMORS,” Med. Phys. 14(2), Mar/Apr 1987, 228-234, which is incorporated herein by reference. Tobias et al. tested various materials to determine which material would best serve as an acoustical window in the skull and ultimately determined polyethylene transmitted a larger percentage of power than other plastics and would likely function well as an ultrasonic window. Further still, Fuller et al., “REAL TIME IMAGING WITH THE SONIC WINDOW: A POCKET-SIZED, C-SCAN, MEDICAL ULTRASOUND DEVICE,” IEEE International Ultrasonics Symposium Proceedings, 2009, 196-199, which is incorporated herein by reference, provides further information regarding sonic windows.

Radiolucency as applied to the present invention allows a clinician to see the anatomy surrounding the clear custom craniofacial implant 10 without “scatter” or interfering artifacts from the implant for diagnosis and follow-up. By another definition of radiolucency, radio waves are able to transmit easily through the clear custom craniofacial implant 10, for example, via Bluetooth or other frequency transmission; which can serve many purposes including, but not limited to, data management and controller telemetry. The provision of radiolucency also allows for the integration of markings (as discussed below) made with radiographic materials, for example, barium sulfate, to be visible in contrast to the remainder of the craniofacial implant to allow for unique device identifiers or unique patient information to be visible on post-operative scans.

Considering the provision of optical lucency in the present clear custom craniofacial implant 10, the ability to optically transmit through the clear custom craniofacial implant 10 allows for visualization of anatomy distal to the clear custom craniofacial implant 10 (as previously described), allows for the potential of higher bandwidth optical links (similar to radio transmission) between proximal adjunct devices, allows for light to be emitted from the clear custom craniofacial implant 10 to adjacent anatomy which could aid in optogenetics, and allows for imaging/therapeutic modalities that rely on light like optical coherence tomography from within the implant

In the newly described form of single-stage cranioplasty in accordance with the present invention, prior to surgery the prefabricated clear custom craniofacial implant 10 is ordered and delivered with oversized dimensions (several extra inches of material along the periphery) to account for additional bone or soft tissue that may be removed and needs to be replaced during the operation—and to, therefore, allow for trimming that is often necessary to optimize fit. After resecting the bony skull region of interest, the surgeon shaves down the oversized, prefabricated clear custom craniofacial implant 10 with a handheld burr to form the final clear craniofacial implant 10′ that will have an exact fit within the resected area (that is, the cranial, craniofacial, and/or facial defect 100).

As will be appreciated based upon the following disclosure, the present method may be used for surgical repair of all cranial, craniofacial, and/or facial defects requiring large-size cranioplasty (e.g., >25 square centimeters). For example, embodiments described herein may be used for designing, forming, modifying and/or implanting clear custom craniofacial implants following benign/malignant skull neoplasm (tumor) resection or any form of bone disease requiring resection and visibility to pertinent anatomy underneath. Further, it is contemplated the present method may be used in order to implant an intercranial device, for example, as disclosed in the '762 Publication, above an area of brain pathology amenable to local intervention by the neurotechnology housed within the implant. Such an implantation of the present method would likely involve the removal of normal bone as opposed to diseased bone.

The present method provides for enhanced visualization related to a tumor, bone edges left behind, dura, brain pulsation, and any potential bleeding sources. The present invention further provides for enhanced visualization of the cranial, craniofacial, and/or facial defect 100 resulting from the removal of a portion of the skull to access the brain (or other tissue), and the reshaped final clear craniofacial implant 10′ for exact positioning in place within the full-thickness defect of the skull. In other words, through the novel use of “clear” craniofacial implants in accordance with the present invention, the intraoperative execution of single-stage implant cranioplasties is improved and enhanced for ideal patient safety, streamlined execution with less time and effort, and reduced patient morbidity related to prolonged operative times. Furthermore, clear implants, such as those described here, contain all the necessary benefits for various implantable neurotechnologies such as neuromodulators, brain medicine delivery, hydrocephalus shunt valves, etc.

In practice, the method of the present invention includes the following steps: a) identifying a diseased portion associated with the craniofacial anatomy; b) generating and/or accessing a computer-readable reconstruction of a patient's anatomy, such as via a preoperative CT scan that includes an anatomical feature, such as a cranial, craniofacial, and/or facial defect, and constructing a 3D model of the anatomy (see FIG. 3A); c) preselecting a resection area on the model; d) determining implant dimensions (can be a few inches greater than the size of the cranial, craniofacial, and/or facial defect) and prefabricating the clear custom craniofacial implant 10 based upon information generated by preoperative scans (see the prefabricating the clear custom craniofacial implant 10 as shown in FIG. 2C); e) cutting out the diseased portion of the skull or that portion of the skull required to access diseased tissue of the brain or other portion of the anatomy, and thereby creating a cranial, craniofacial, and/or facial defect 100 (see FIG. 2A and 2B); f) removing the diseased anatomical feature (in addition to step (e), if further necessary); g) positioning the prefabricated clear custom craniofacial implant 10 over the cranial, craniofacial, and/or facial defect 100 created by the removal of the diseased anatomical feature (see FIG. 2C); h) tracing cut lines 12 with a hand-held sterile marker on the prefabricated clear custom craniofacial implant 10 as it lies in-situ over the cranial, craniofacial, and/or facial defect 100 (this advantage being permitted as a result of the clear construction of the craniofacial implant 10 used in accordance with the present invention (see FIG. 2D)); i) cutting the prefabricated clear custom craniofacial implant 10 along the tracing cut lines 12 for optimal fit of the prefabricated clear custom craniofacial implant 10 along the cranial, craniofacial, and/or facial defect 100 and to create the final-size/shape of clear craniofacial implant 10′ for exact fit (see FIG. 2E); j) attaching the final clear craniofacial implant 10′ to the patient 102 (see FIG. 3F); k) obtaining a post-operative image of the patient 102 and the attached final clear craniofacial implant 10′, such as via a CT scan (see FIGS. 3A and 3B respectively showing a pre-operative and post-operative CT scans showing large left sided skull tumor and post-resection views showing ideal symmetry and optimal implant location using a clear custom craniofacial implant). Of note, and with reference to FIGS. 3A and 3B, one can see that the bone defect ended up being much larger in size as compared to what one visualizes on pre-operative CT scan—and thus the need for the single-stage cranioplasty method being described here.

With the exception of steps (g), (h) and (i), the steps associated with the present invention are conventional and variations may be made in accordance with surgical preferences and advancements in medicine. As such, and with reference to FIGS. 2C-2F these steps are described in further detail below. After removing the diseased anatomical feature, the prefabricated clear custom craniofacial implant 10 is prepared for attachment near the healthy portions of the patient's anatomy. In particular, and with the cranial, craniofacial, and/or facial defect 100 open, the surgeon will retrieve the prefabricated clear custom craniofacial implant 10. Based upon, and in consideration of, the unique anatomy of the full-thickness defect within the skull 106 and the outer surface of the skull 106 surrounding the cranial, cranio facial, and/or facial defect 100, the surgeon places the prefabricated clear custom craniofacial implant 10 over and within the space defined by the cranial, cranio facial, and/or facial defect 100 in a desired orientation. Because the prefabricated custom craniofacial implant 10 is “clear”, the surgeon is now able (unlike before with the commonly-available, “opaque” implants) to view the periphery 108 of the defect 100 through the prefabricated clear custom craniofacial implant 10 in real-time and uses a sterile intra-operative marking device (for example, a marking pen) 60 to trace the periphery of the cranial, craniofacial, and/or facial defect 100 directly onto the prefabricated clear custom craniofacial implant 10—as opposed to the current day practice of using a hand-made template or cutting guide. While tracing with a marking device is disclosed in accordance with a preferred embodiment, it is appreciated the creation of the tracing cut lines may be achieved via various other mechanisms for example, etching or otherwise marking the implant.

The surgeon then trims the prefabricated clear custom craniofacial implant 10 along the tracing cut line 12 with an intraoperative contour drill 50. Trimming is achieved using various medical grade tools well known to those skilled in the art, and it is appreciated surgeons will use various trimming techniques depending upon their preferences. Once the prefabricated clear custom craniofacial implant 10 is fully trimmed and has become the final clear craniofacial implant 10′, the final clear craniofacial implant 10′ is secured to the skull 106 using techniques well known to those skilled in the art providing durable fixation.

The present method exponentially reduces the time necessary for sizing the prefabricated clear custom craniofacial implant 10 relative to the removed bone. The method relies on the use of a fully translucent and clear craniofacial implant 10 and associated techniques for matching the clear craniofacial implant 10 to the cranial, craniofacial, and/or facial defect 100. As described above, single-stage cranioplasties are performed to reconstruct large defects in the skull following removal of unanticipated amounts of cranial bone and/or soft tissue. With this in mind, the present method may be used for reconstructing all craniofacial defects with clear craniofacial implants for an ideal result unlike ever before with improved patient satisfaction, reduced morbidity, lessened risk for bleeding, reduced operating room costs, and enhanced patient safety. Accordingly, the present method may be used by all surgeons in performing single-stage cranioplasty following resection of bone disease for which the exact defect size is unknown in advance.

As shown with reference to FIG. 4, and as discussed above, various neurological devices 20, for example, monitoring and treatment devices, such as remote pressure monitor, may also be incorporated within this novel clear implant and are safe from injury during size modification solely due to the translucency and enhanced visibility provided by the clear custom cranio facial implant. The neurological devices incorporated within the clear implant may provide visual monitoring for potential tumor recurrence (i.e., ultrasound, OCT (Optical Coherence Tomography)), may provide battery-powered treatment options for epilepsy (i.e., NeuroPace RNS system), Alzheimer's, or Parkinson's with electricity and/or battery-powered medicinal delivery options with oncological methods such as convection enhanced delivery (CED) and local medicine delivery. Such abilities are preferably achieved using innovative modalities disclosed by Gordon et al. in International Patent Application PCT/US2016/030447, filed May 2, 2017, entitled “LOW PROFILE INTERCRANIAL DEVICE,” (published as WO 2017/039762), and U.S. patent application Ser. No. 15/669,268, filed Aug. 4, 2017, entitled “METHOD FOR MANUFACTURING A LOW-PROFILE INTERCRANIAL DEVICE AND THE LOW-PROFILE INTERCRANIAL DEVICE MANUFACTURED THEREBY” (published as U.S. Patent Application Publication No. 2018/0055640), which claims the benefit of U.S. Provisional Patent Application 62/381,242, filed Aug. 30, 2016, entitled “METHOD FOR MANUFACTURING A LOW-PROFILE INTERCRANIAL DEVICE AND THE LOW-PROFILE INTERCRANIAL DEVICE MANUFACTURED THEREBY,” all of which are incorporated herein by reference. Further details can be found in the landmark publication by Dr. Gordon and team entitled, “First In-human Experience with Complete Integration of Neuromodulation Device Within a Customized Cranial Implant.” (Operative Neurosurgery 2017).

Also, computer-assisted and/or surgical methods may be integrated with the use of the clear craniofacial implant as described above. The computer-assisted robot-assisted surgery system may provide a user enhanced implant reconstruction experience, for example, providing a surgeon unprecedented, immediate visual feedback and allowing single-stage cranioplasty and all related craniomaxillofacial reconstruction for scenarios related to skull neoplasms, etc.—in situations where the tumor defect is not known beforehand, but where a clear custom implant is needed requiring on-table modification via computer-assisted and/or robot-assisted surgery system guidance. Such guidance is preferably achieved using techniques disclosed in U.S. Patent Application Publication No. 2017/0000505, entitled “Computer-Assisted Craniomaxillofacial Surgery,” which is incorporated herein by reference. The previously described computer-assisted modality, together with the newfound “clear” implant advantages, may act synergistically moving forward for improved outcomes. Even though the computer-assisted and/or robot-assisted system may provide the guidance as to where modification should occur, the “clear” implant with complete transparency will help the surgeon confirm the efficacy of the computer-assisted and/or robot-assisted system by seeing the skull edges underneath when placed in-situ.

FIGS. 2A-2F, 3A, and 3B illustrate together a representative of the present method for single-stage cranioplasty reconstruction using a clear craniofacial implant 10 and the final result with the embedded final clear craniofacial implant 10′. After generating computer-readable reconstruction of a patient's anatomy, preselecting a resection area on the model, determining implant dimensions (can be a few millimeters greater than the size of the cranial, craniofacial, and/or facial defect), and prefabricating the custom craniofacial implant 10 based upon information generated by known computer-assisted and/or robot-assisted surgical systems, the surgical procedure is initiated with the resection of the skull 106, which leaves behind an anatomical feature of interest, such as a cranial, craniofacial, and/or facial defect 100 with varying thickness which is not consistently smooth due to the manual cutting aspect with craniotomy by a neurosurgery.

Thereafter, the prefabricated clear custom cranio facial implant 10 is aligned with the unique anatomical features along the periphery 108 of the cranial, craniofacial, and/or facial defect 100 and the prefabricated clear custom craniofacial implant 10 is positioned over the cranial, craniofacial, and/or facial defect 100. The boundaries 108 of the cranial, craniofacial, and/or facial defect 100 are then traced on the prefabricated clear custom cranio facial implant 10 in the form of the tracing cut lines 12 and the prefabricated clear custom craniofacial implant 10 is trimmed in accordance with the tracing cut lines 12 to create the final clear craniofacial implant 10′. Cutting (that is, the cutting of the cranio facial implant 10 to achieve a trimmed craniofacial implant 10 of a desired size and shape) is achieved in a conventional manner using various cutting, sanding and processing machines known to those skilled in the art. It is appreciated that such cutting may include non-manual techniques, for example, as might be performed with computer controlled robotic systems, such as those described by Dr. Gordon's team in U.S. Patent Application Publication No. 2017/0252169, entitled “A Cutting Machine for Resizing New Implants During Surgery,” which is incorporated herein by reference. The result of such a single-stage cranioplasty reconstruction according to an embodiment is shown in FIG. 3B with the final clear cranio facial implant 10′ attached to the patient's anatomy and showing an exact fit with the absence of gaps along the periphery of the “implant-cranial bone interface.” However, future methods for clear implant size modification may include computer-assistance and/or robot-assistance as disclosed in U.S. Patent Application Publication No. 2017/0000505, entitled “Computer-Assisted Craniomaxillofacial Surgery.”

Further to the clear craniofacial implant described above, it is appreciated the clear craniofacial implant may be modified in a manner adding even greater functionality without detracting from the ability of a surgeon to advantageously employ the trace lines and cutting described above to achieve an optimal fit. For example, and with reference to FIG. 4, clear craniofacial implant 10 may be provided with laser etching(s) or dyed marking(s) 30 indicating the desired implanted orientation of the clear craniofacial implant (that is, ventral, dorsal, left/right lateral) relative to the patient anatomy, or patient specific landmarks. Such etching(s) or marking(s) may be in the form of a compass-shape, diamond, a triangle, a straight-line or any other marking that would be readily understood and identified by a surgeon. The etching(s) or marking(s) could be adapted to a predetermined part of the anatomy, i.e., nasal bone, a suture intersection, etc., wherein the specific anatomy would be determined during the planning stages of the surgical procedure. It is also appreciated etching(s) or marking(s) could be used to identify anatomy beneath the defect, a tumor sight, an aneurysm location, planned integration of other neurological devices, or a functional component (for example, seizure focus, enlarged ventricle with hydrocephalus, shunts, catheters, leads, pumps, drips, flow, etc.), as well as the orientation of such a functional component. For example, the etching(s) or marking(s) could be used in the identification of seizure focus, enlarged ventricle with hydrocephalus, shunts, catheters, leads, pumps, drips, flow, etc. Still further, the etching(s) or marking(s) may be employed on the clear craniofacial implant to identify prescriptions, disease state, date of surgery, type of neurotechnology housed within the implant, etc. It is also appreciated such etching(s) or marking(s) could be used in various combinations to achieve various goals at one time.

It should be appreciated that while both the neurological device(s) 20 and the various etching(s) or marking(s) 30 are shown in FIG. 5 on a single craniofacial implant 10, various combinations of neurological device(s) 20 and/or etching(s)/marking(s) 30 may be used in accordance with the present invention.

Considering the integration of both the neurological device(s) 20 and the various etching(s) or marking(s) 30 into the craniofacial implant 10 in accordance with the present invention, it is contemplated such craniofacial implants may be manufactured in various manners to achieve optimal fit and functionality. In accordance with one embodiment, the neurological device(s) 20 and the various etching(s) or marking(s) 30 are integrated into the body of the craniofacial implant through the use of barium sulfite integrated into craniofacial implants composed of PMMA. In accordance with another embodiment, neurological device(s) 20 and the various etching(s) or marking(s) 30 are integrated into the craniofacial implant 10, for example, through the application of 3D printing (additive manufacturing) techniques with layers or specific areas of radiographic elements or markings incorporated into the structure of the craniofacial implant 10. In accordance with other embodiments, the craniofacial implant 10 may be manufactured through the application of 3D printing, wherein specific shapes adapted for cranial restoration and augmentation are incorporated into the craniofacial implant 10; including, but not limited to, augmentation optimized for the integration of neurological device(s) 20, the provision of etching(s) or marking(s) 30, and/or the surgical integration of other complimentary devices. Liquid molding may also be employed, wherein the liquid molding techniques are used to create specific shapes adapted for cranial restoration and augmentation; including, but not limited to, augmentation optimized for the integration of neurological device(s) 20, the provision of etching(s) or marking(s) 30, and/or the surgical integration of other complimentary devices. Still further vacuum assisted liquid molding may be employed, wherein vacuum assisted liquid molding techniques are used to create specific shapes adapted for cranial restoration and augmentation; including, but not limited to, augmentation optimized for the integration of neurological device(s) 20, the provision of etching(s) or marking(s) 30, and/or the surgical integration of other complimentary devices. Mechanically altered manufacturing methods combining molding, liquid molding, 3D printing may also be used in creating craniofacial implants 10 with specific shapes adapted for cranial restoration and augmentation; including, but not limited to, augmentation optimized for the integration of neurological device(s) 20, the provision of etching(s) or marking(s) 30, and/or the surgical integration of other complimentary devices via CNC (Computer Numerical Control) machining, laser, robot, robotic laser. Such craniofacial implants 10 could also be manufactured using milling techniques, wherein blocks of an implant material are milled via CNC machines, laser, robot, and/or robotic laser to create specific shapes adapted for cranial restoration and augmentation; including, but not limited to, augmentation optimized for the integration of neurological device(s) 20, the provision of etching(s) or marking(s) 30, and/or the surgical integration of other complimentary devices.

The described methods of the embodiments may be utilized during a surgical procedure, such as a surgical implantation procedure for various forms of craniomaxillo facial surgery and/or neurosurgery including an implant-based cranioplasty. Accordingly, the implant may be a custom, clear craniofacial implant made of either alloplastic biomaterials or biologic tissue engineered cells as described above and a being, such as a human being, on whom the surgical procedure is performed. In other words, the clear craniofacial implant is material-agnostic and only requires complete translucency and optical clarity.

The method described above overcomes the deficiencies of the prior art by providing a method that reduces inaccuracies; in particular, performance, stability, simplicity, environmental benefit, cost, etc. When using an opaque implant or bone graft for reconstruction, as used in the prior art, a template may be used to represent the size and shape of the cranial, craniofacial, and/or facial defect—usually paper or cloth from other sterile product in the operating room. When translating the template to the implant orientation changes (anterior, posterior, medial, lateral, superior, inferior, or rotational) occur and the potential for infection and positional rotation increases. Furthermore, the “opaque” nature of the implant prevents the surgeon from seeing the underlying brain and/skull underneath in relation for size assessment, Dural pulsations symbolizing normal brain function, and/or surgical bleeding. These disadvantages have been described and published by the inventor in Gordon C R, et al., “Discussion of Usefulness of an Osteotomy Template for Skull Tumorectomy and Simultaneous Skull Reconstruction,” The Journal of Craniofacial Surgery, Vol. 27, No. 6, Sept. 2016. Simultaneously each skull or bony skeleton has unique anatomy that implants and/or grafts are contoured to match specifically. The result is that using templates to translate the cranial, craniofacial, and/or facial defect to an “opaque” implant loses orientation and the implant and/or graft does not fit correctly, either the contours don't match with the native skull or the shape is incorrect and requires additional modification. If not using a template, the surgeon is just “eyeballing” the size and shape of the cranial bone defect which requires even more rounds of modification and inferior fit. More importantly, oncological principles are being ignored when using a cutting template.

The ability to directly match up the cranial, craniofacial, and/or facial defect and the implant by using “optically clear” implants for the very first time, in accordance with the present invention, improves orientation and decreases rounds of modification and enhances one visibility as related to brain or bone bleeding underneath. In addition, because the present method employs a “clear implant” and/or graft—which can be held uniquely over the cranial, craniofacial, and/or facial defect created during surgery—the new size and shape of the cranial, craniofacial, and/or facial defect is more accurately translated to the implant and/or graft; for example, holding the implant over the cranial, craniofacial, and/or facial defect and tracing the cranial, craniofacial, and/or facial defect with a sterile marker. Because the perimeter of the implant rests on the patient's native craniofacial skeleton in the margin between the cranial, craniofacial, and/or facial defect and the edges of the over-sized clear implant, the orientation of the native skull is translated to the implant in a way that was previously impossible when transferring a template from the patient to the current-day implants, which are all “opaque” and provide zero transparency.

In addition to inaccuracy issues, the more accurately the cranial, craniofacial, and/or facial defect can be translated to the implant/graft, the less rounds of modification are required to get an implant/graft to an acceptable size and contour, thereby equating to shortened operative times and minimizing risks for infection and sterility. In fact, traditional methods have demonstrated the need for up to 80 minutes by the inventor Dr. Chad R. Gordon (see Berli J U, et al., “Immediate Single-Stage Cranioplasty Following Calvarial Resection for Benign and Malignant Skull Neoplasms Using Customized Craniofacial Implants,” The Journal of Craniofacial Surgery, Vol. 26, No. 5, Sept. 2015). By utilizing the clear custom implant described herein, the operative time can be cut down substantially with improved accuracy for direct translation of cranial, craniofacial, and/or facial defect to implant/graft with much improved speed and efficiency.

Still further, operating rooms average a cost of $62/minute not including anesthesia, salaries, and some other costs (Shippert, R. A Study of Time-Dependent Operating Room Fees and How to Save $100,000 by Using Time-Saving Products. Am J. of Cosmetic Surgery, Vol. 22, No. 1, 2005. Available online July 2013. Macario, A. What does One Minute of Operating Room Time Cost? J. of Clinical Anesthesia, Vol. 22, 2010. Available online July 2013). Shortening surgery by use of a novel clear implant saves money in this setting as well as significant labor.

Ultimately, and considering accuracy is improved, the ideal contour and reconstruction sought by the surgeon and the patient are more achievable with clear implants in single-stage cranioplasty unlike ever before. Further still, it is appreciated the concepts underlying the present invention may be applied to multi-stage cranioplasties, with or without a neurological device being integrated into the clear craniofacial implant. Additionally, the “optical clear” advantage allows unimpeded transmittance of ultrasound and/or wireless ECOG transmission, as reported by Gordon et al. in “First In-human Experience with Complete Integration of Neuromodulation Device Within a Customized Cranial Implant” as discussed above.

While the preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, it is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention. 

1. A method for performing a cranioplasty, comprising: prefabricating a clear craniofacial implant based upon information generated by preoperative scans; creating a cranial, craniofacial, and/or facial defect; tracing cut lines on the clear craniofacial implant; cutting the clear custom craniofacial implant along the traced cut lines for optimal fit of the craniofacial implant along the cranial, craniofacial, and/or facial defect; and attaching the final clear craniofacial implant to the cranial, cranio facial, and/or facial defect.
 2. The method according to claim 1, wherein the clear craniofacial implant is composed of PMMA.
 3. The method according to claim 1, further including the step of positioning the clear craniofacial implant over the cranial, craniofacial, and/or facial defect prior to the step of tracing cut lines.
 4. The method according to claim 3, wherein the step of positioning includes placing the clear craniofacial implant over the cranial, craniofacial, and/or facial defect in a desired orientation based upon a unique anatomy of an outer surface of a skull surrounding the cranial, craniofacial, and/or facial defect.
 5. The method according to claim 3, wherein the step of tracing cut lines includes tracing cut lines on the clear craniofacial implant as the clear craniofacial implant lies over the cranial, craniofacial, and/or facial defect, wherein a boundary of the cranial, craniofacial, and/or facial defect is viewable through the clear craniofacial implant thereby allowing for visible tracing.
 6. The method according to claim 5, wherein the step of tracing includes tracing a periphery of the cranial, craniofacial, and/or facial defect directly onto the clear craniofacial implant using a sterile intra-operative marking pen.
 7. The method according to claim 5, wherein the step of positioning includes placing the clear craniofacial implant over the cranial, craniofacial, and/or facial defect in a desired orientation based upon a unique anatomy of an outer surface of a skull surrounding the cranial, craniofacial, and/or facial defect which is visible through the clear craniofacial implant.
 8. The method according to claim 7, wherein the step of cutting includes trimming the clear craniofacial implant using medical grade tools, computer-assisted and/or robot-assisted devices in an operating room along boundaries defined by the traced cut lines.
 9. The method according to claim 1, wherein the step of cutting includes trimming the clear craniofacial implant using medical grade tools, computer-assisted and/or robot-assisted devices in an operating room along boundaries defined by the traced cut lines.
 10. The method according to claim 1, further including the steps of identifying a diseased portion associated with aberrant craniofacial and/or brain anatomy and generating a computer-readable reconstruction of a patient's anatomy associated with the diseased portion for the purpose of designing and fabricating the clear craniofacial implant.
 11. The method according to claim 10, wherein the step of creating a cranial, craniofacial, and/or facial defect includes cutting out a diseased portion of a skull to be replaced with the clear craniofacial implant.
 12. The method according to claim 1, wherein the step of creating a cranial, craniofacial, and/or facial defect includes cutting out a portion of a skull to be replaced with the clear cranio facial implant.
 13. The method according to claim 1, wherein a neurological device with constant or intermittent function is incorporated within the clear craniofacial implant.
 14. The method according to claim 13, wherein the step of prefabricating a clear craniofacial implant includes incorporating a neurological device within the clear craniofacial implant via 3D printing, liquid molding, vacuum assisted liquid molding, mechanically altered manufacturing methods, milling techniques, or combination thereof.
 15. The method according to claim 13, wherein the neurological device is a monitoring device or device for treating a neurological disorder.
 16. The method according to claim 1, wherein the cranioplasty is a single-stage cranioplasty.
 17. The method according to claim 1, wherein the clear craniofacial implant includes an etching or a marking.
 18. The method according to claim 17, wherein the step of prefabricating a clear craniofacial implant includes incorporating the etching or the marking via 3D printing, liquid molding, vacuum assisted liquid molding, mechanically altered manufacturing methods, miffing techniques, or combination thereof.
 19. The method according to claim 17, wherein the etching or marking indicates a desired implanted orientation of the clear cranio facial implant.
 20. The method according to claim 17, wherein the etching or marking identifies anatomy beneath the defect, a tumor sight, an aneurysm location, or a functional component.
 21. The method according to claim 17, wherein the etching or marking identifies a prescription, a disease state, or a date of surgery, or type of implantable neurotechnology housed within the clear craniofacial implant.
 22. The method according to claim 1, wherein the clear cranio facial implant is sonolucent.
 23. The method according to claim 1, wherein the clear cranio facial implant is radiolucent.
 24. A craniofacial implant made in accordance with the method comprising: prefabricating a clear craniofacial implant based upon information generated by preoperative scans; creating a cranial, craniofacial, and/or facial defect; tracing cut lines on the clear craniofacial implant; and cutting the clear custom craniofacial implant along the traced cut lines for optimal fit of the craniofacial implant along the cranial, craniofacial, and/or facial defect.
 25. The craniofacial implant according to claim 24, wherein the clear craniofacial implant is composed of PMMA.
 26. The craniofacial implant according to claim 24, wherein a neurological device with constant or intermittent function is incorporated within the clear craniofacial implant.
 27. The craniofacial implant according to claim 26, wherein the neurological device is a monitoring device or device for treating a neurological disorder.
 28. The craniofacial implant according to claim 24, wherein the clear craniofacial implant includes an etching or a marking.
 29. The craniofacial implant according to claim 28, wherein the etching or marking indicates a desired implanted orientation of the clear craniofacial implant.
 30. The craniofacial implant according to claim 28, wherein the etching or marking identifies anatomy beneath the defect, a tumor sight, an aneurysm location, or a functional component.
 31. The craniofacial implant according to claim 28, wherein the etching or marking identifies a prescription, a disease state, or a date of surgery, or type of implantable neurotechnology housed within the clear craniofacial implant.
 32. The craniofacial implant according to claim 24, wherein the clear craniofacial implant is sonolucent.
 33. The craniofacial implant according to claim 24, wherein the clear craniofacial implant is radiolucent.
 34. A method for making a craniofacial implant, comprising: prefabricating a clear craniofacial implant based upon information generated by preoperative scans; creating a cranial, craniofacial, and/or facial defect; tracing cut lines on the clear craniofacial implant; and cutting the clear custom craniofacial implant along the traced cut lines for optimal fit of the craniofacial implant along the cranial, craniofacial, and/or facial defect.
 35. The method according to claim 34, wherein the clear craniofacial implant is composed of PMMA.
 36. The method according to claim 34, wherein a neurological device with constant or intermittent function is incorporated within the clear craniofacial implant.
 37. The method according to claim 36, wherein the step of prefabricating a clear craniofacial implant includes incorporating a neurological device within the clear craniofacial implant via 3D printing, liquid molding, vacuum assisted liquid molding, mechanically altered manufacturing methods, milling techniques, or combination thereof.
 38. The method according to claim 36, wherein the neurological device is a monitoring device or device for treating a neurological disorder.
 39. The method according to claim 34, wherein the clear craniofacial implant includes an etching or a marking.
 40. The method according to claim 39, wherein the step of prefabricating a clear craniofacial implant includes incorporating the etching or the marking via 3D printing, liquid molding, vacuum assisted liquid molding, mechanically altered manufacturing methods, milling techniques, or combination thereof.
 41. The method according to claim 39, wherein the etching or marking indicates a desired implanted orientation of the clear cranio facial implant.
 42. The method according to claim 39, wherein the etching or marking identifies anatomy beneath the defect, a tumor sight, an aneurysm location, or a functional component.
 43. The method according to claim 39, wherein the etching or marking identifies a prescription, a disease state, or a date of surgery, or type of implantable neurotechnology housed within the clear cranio facial implant.
 44. The method according to claim 34, wherein the clear craniofacial implant is sonolucent.
 45. The method according to claim 34, wherein the clear craniofacial implant is radiolucent. 